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| SEH > SEC Filings for SEH > Form 10-K on 14-Jan-2009 | All Recent SEC Filings |
14-Jan-2009
Annual Report
The following discussion and analysis of our financial condition and results
of operations contains "forward-looking statements". You should read the
following discussion of our financial condition and results of operations with
"Selected Financial Data" and our consolidated financial statements and related
notes thereto. We have based our forward-looking statements about our markets
and demand for our products and future results on assumptions that we consider
reasonable. Actual results may differ materially from those suggested by our
forward-looking statements for various reasons including those discussed in
"Cautionary Statements Concerning Forward-Looking Statements" and Item 1A.
Business Overview
Spartech is an intermediary processor of engineered thermoplastics which
converts base polymers or resins purchased from commodity suppliers into
extruded plastic sheet and rollstock, thermoformed packaging, specialty film
laminates, acrylic products, specialty plastic alloys, color concentrates and
blended resin compounds, and injection molded and profile extruded products for
customers in a wide range of markets. We have facilities located throughout the
United States, Canada, Mexico and Europe that are organized into three segments
and one group as follows:
% of
2008 Sales
Custom Sheet and Rollstock 45
Packaging Technologies 20
Color and Specialty Compounds 30
Engineered Products 5
We assess net sales changes using three major drivers: underlying volume, the
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demand will remain weak through this period. We believe our aggressive cost
reduction actions and financial discipline will enable us to effectively manage
through the challenging economy. We expect to emerge from this environment a
stronger and better positioned Company to support future long-term profitable
growth.
Results of Operations
Comparison of 2008 and 2007
Consolidated Summary
Net sales were $1,398.9 million and $1,452.0 million in 2008 and 2007,
respectively, representing a 4% decrease in 2008. The decrease was caused by:
Underlying volume (13 )%
Prior year additional week (2 )
Creative acquisition 3
Price/Mix 8
(4 )%
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Our underlying volume decreased 191 million pounds, or 13%, because of lower
end market demand and decreases in discretionary spending in the economy. Of the
191 million pounds decrease, 61% occurred in the transportation and recreation
and leisure markets. Our volume sold to the transportation market declined 25%
from the prior year due mostly to lower volumes to the automotive sector. Volume
sold to the recreation and leisure market was lower by 20%, reflecting decreases
in sales to recreational vehicles, pools, spas and marine sectors of this
market. Most of the remaining 39% of our underlying volume decrease occurred in
the packaging market which declined 10% from the prior year and our building and
construction market which was lower by 6% from the prior year. The decrease in
the packaging market was caused by lower purchases in the industrial and food
packaging sectors of this market, and the decrease in the building and
construction market reflected lower sales to the residential sector which were
partially offset by an increase in volume sold to the commercial sector of this
market.
The decrease in volume from the additional week reflects 53 weeks of sales
activity in 2007 compared to 52 weeks in 2008. The increase from the Creative
acquisition represents the full-year impact of sales dollars from this
acquisition which occurred in September 2007. Our sales comparison benefited
from price/mix due mostly to increases in sales dollars from the pass-through of
resin cost increases.
The following table presents net sales, components of cost of sales, and the
resulting gross margin in dollars and on a per pound sold basis for 2008 and
2007. Cost of sales presented in the consolidated statements of operations
includes material and conversion costs and excludes amortization of intangible
assets. The material and conversion cost components of cost of sales are
presented in the following table. We have not presented these components as a
percentage of net sales because a comparison of this measure is distorted by
changes in resin costs that are typically passed through to customers as changes
to selling prices. These changes can materially affect the percentages but do
not present complete performance measures of the business.
2008 2007
Dollars and Pounds (in millions)
Net sales $ 1,398.9 $ 1,452.0
Material costs 948.2 952.1
Material margin 450.7 499.9
Conversion costs 324.8 336.3
Gross margin $ 125.9 $ 163.6
Pounds Sold 1,236 1,436
Dollars per Pound Sold
Net sales $ 1.132 $ 1.011
Material costs 0.767 0.663
Material margin 0.365 0.348
Conversion costs 0.263 0.234
Gross margin $ 0.102 $ 0.114
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The increases in net sales and material costs per pound in 2008 were caused
by significant increases in our resin costs during the year which we passed
along to customers as higher selling prices. The 1.7 cent per pound increase in
material margin reflects sales mix changes and the positive impact of our margin
enhancement initiative. Our conversion costs per pound increased 2.9 cents
because of the decrease in sales volume. Excluding the Creative acquisition, our
conversion cost dollars decreased 7% due to the volume decline and the impact of
our manufacturing cost optimization initiative on reducing our labor-related
costs. Labor-related costs represent approximately half of our total conversion
costs, and this initiative resulted in approximately $15 million of lower labor
costs in 2008. We expect another $10 million of lower labor costs in 2009
compared to 2008 due to the full year impact of our initiative.
Selling, general and administrative expenses were $92.6 million in 2008,
representing an $8.7 million increase over the prior year. The increase was
caused by the full-year impact of our Creative acquisition, higher information
technology expenses to support our company-wide Oracle information system
implementation, higher professional fees to support our turnaround initiatives
and higher bad debts expense, the impacts of which were partially offset by the
extra week and a charge associated with the resignation of the Company's former
President and Chief Executive Officer, both of which occurred in 2007.
Amortization of intangibles was $5.2 million in 2008 compared to $4.5 million
in 2007. The increase was due to the prior year Creative acquisition. We
estimate a decrease to $4.5 million of amortization in 2009, which reflects the
impact of our current year asset impairments and certain assets that became
fully amortized in 2008.
The $238.6 million of goodwill impairments and $15.5 million of fixed asset
and other intangible asset impairments in 2008 reflect non-cash charges which
were incurred in our Custom Sheet and Rollstock, Color and Specialty Compounds
and Engineered Products business segments and group. Additional details
regarding these impairment charges are discussed in Notes 4 and 5 to the
consolidated financial statements.
Restructuring and exit costs were $2.3 million in 2008 and $1.3 million in
2007. The 2008 costs are mostly comprised of employee severance, equipment
moving expenses and accelerated depreciation resulting from the Company's
manufacturing cost optimization initiative. For announced restructuring
initiatives as of November 1, 2008, the Company expects to incur approximately
$1.8 million of additional restructuring costs, primarily cash-related equipment
moving and installation expenses. The 2007 costs primarily represent employee
severance, equipment moving expenses and accelerated depreciation associated
with the shut-down of three former sheet production facilities and the movement
of the business into the Company's newly constructed facility in Greenville,
Ohio.
The Company reported a $228.3 million operating loss in 2008 which compared
to $72.4 million of operating income in 2007. The $300.8 million decrease
reflected the $238.6 million goodwill impairment in 2008, the $14.0 million
increase in fixed asset and other intangible asset impairments and $1.1 million
increase in restructuring and exit costs. The remaining $47.1 million decrease
was caused by the decline in sales volume which was mitigated somewhat by higher
material margins and reductions in conversion costs.
Interest expense, net was $20.6 million in 2008 and $17.6 million in 2007.
The higher expense in 2008 was due to the increase in debt to fund the Creative
acquisition and stock repurchases during the fourth quarter of 2007 and the
first quarter of 2008.
Our effective tax rate in 2008 was impacted by the significant goodwill
impairments, some of which were not tax deductible. Excluding the goodwill
impairments, our effective tax rate was 32% in 2008 which compared to 38% in
2007. Our 2008 effective tax rate was positively impacted by domestic state and
foreign tax law changes in the first quarter of 2008. We estimate our 2009 tax
rate to be in the approximate range of 38% to 39%.
We reported a net loss of $192.1 million in 2008 and net earnings of
$33.8 million in 2007. These amounts reflect the impact of the items previously
discussed.
Custom Sheet and Rollstock Segment
Net sales were $637.1 million and $674.8 million in 2008 and 2007,
respectively, representing a 6% decrease in 2008. This decrease was caused by:
Underlying volume (12 )%
Prior year additional week (2 )
Price/Mix 8
(6 )%
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Most of our underlying volume decrease in this segment occurred in the
transportation, recreation and leisure and building and construction markets.
Volume sold to the transportation market decreased 22% and occurred within the
automotive and heavy truck sectors of this market. The segment's volume to the
recreation and leisure market was lower by 22% reflecting lower sales of
recreational vehicles, spas, pools and marine products. We experienced an 18%
decline in volume to the building and construction market from decreases in
sales of residential construction-related products. The price/mix benefit was
mostly from sales dollar increases from the pass-through of resin cost
increases.
This segment reported an operating loss of $100.1 million in 2008 and
operating income of $44.2 million in 2007. This comparison reflects
$119.2 million of asset impairments in 2008. The remaining $25.1 million
decrease in operating earnings was caused by the lower volume and lower material
margins in the early portion of 2008 because of a significant increase in resin
costs that were not passed along to customers in a timely manner. These adverse
factors were partially offset by lower costs from our manufacturing cost
optimization initiative and higher margins from our margin enhancement
initiative in the later portion of 2008.
Packaging Technologies Segment
Net sales were $274.4 million and $253.7 million in 2008 and 2007,
respectively, representing an 8% increase in 2008. This increase was caused by:
Underlying volume (8 )%
Prior year additional week (2 )
Creative acquisition 13
Price/Mix 5
8 %
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The decrease in underlying volume reflected a 7% decline to packaging-related
markets, which represent approximately three-fourths of this segment's total
sales, and a 13% decline in the remaining portion of this segment sold to
non-packaging related markets. Our Creative acquisition provided additional
sales of $34.1 million in 2008 versus 2007. The price/mix benefit was mostly
from sales dollar increases from the pass-through of resin cost increases.
Operating earnings were $18.8 million in 2008 compared to $26.1 million in
2007. This decrease was caused by the decline in volume and lower underlying
material margins from significant increases in resin costs in 2008 that were not
passed along to customers in a timely manner due largely to indexed pricing
arrangements. These factors were partially offset by additional earnings
contributed from Creative and benefits from our manufacturing cost optimization
initiative.
Color and Specialty Compounds Segment
Net sales were $414.0 million and $446.8 million in 2008 and 2007,
respectively, representing a 7% decrease in 2008. This decrease was caused by:
Underlying volume (16 )%
Prior year additional week (2 )
Price/Mix 11
(7 )%
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Approximately three-fourths of the sales volume decline in this segment occurred from lower sales of compounds to the automotive market and industrial packaging market. These sectors of our end markets represented about half of this segment's sales volume and were lower by 27% and 23% for automotive and industrial packaging, respectively, from 2007. These losses were somewhat mitigated by an increase in volumes sold to the commercial construction market. The price/mix benefit was mostly from sales dollar increases from the pass-through of resin cost increases.
This segment reported an operating loss of $98.0 million in 2008 and
operating income of $23.1 million in 2007. This comparison reflects
$112.7 million of asset impairments in 2008. The remaining $8.4 million decrease
in operating earnings was caused by the lower volume which was offset somewhat
by higher material margins from improved mix and our margin enhancement
initiative and lower costs from our manufacturing cost optimization initiative.
Engineered Products Group
Net sales were $73.4 million and $76.7 million in 2008 and 2007,
respectively, representing a 4% sales decrease in 2008. This decrease was caused
by:
Underlying volume (5 )%
Prior year additional week (2 )
Price/Mix 3
(4 )%
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The underlying volume decline in this group was primarily caused by lower
sales of lawn mower wheels due to decreases in discretionary spending in the
economy. The price/mix benefit mostly resulted from sales dollar increases from
the pass-through of resin cost increases.
This group reported a $13.3 million operating loss in 2008 versus
$9.6 million of operating income in 2007. Of the $22.9 million decrease,
$21.6 million was caused by 2008 asset impairments. The remaining $1.3 million
resulted from the lower volume of lawn mower wheels sold.
Corporate
Corporate expenses are reported as selling, general and administrative
expenses in the consolidated statements of operations and include corporate
office expenses, information technology costs, professional fees and the impact
of foreign currency exchange. Corporate expenses were $35.8 million in 2008
compared to $30.6 million in the prior year. Corporate expenses increased in
2008 from higher depreciation expense, information technology related costs
associated with our company-wide Oracle information system implementation and
higher professional fees to support our turnaround initiatives.
Comparison of 2007 and 2006
Consolidated Summary
Net sales were $1,452.0 million and $1,485.6 million for the years ended 2007
and 2006, respectively, representing a 2% decrease in 2007. The causes of this
percentage decrease were as follows:
Underlying volume (4 )%
Volume from additional week 2
Acquisition of business -
Price/Mix -
(2 )%
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The decrease in underlying volume was caused by lower sales of compounds to
the automotive sector of the transportation market, color concentrates to the
packaging market and lower sales of sheet to the recreation and leisure market,
the residential sector of the building and construction market and the heavy
truck and automotive sectors of the transportation market. These declines were
partially offset by increases in sales of thermoformed product to the packaging
market, sheet to the refrigeration sector of the appliance and electronics
market and compounds to the commercial building and construction market.
Disruptions from the Greenville sheet consolidation also contributed to the
decline in sales volume during 2007. Sales volume from the additional week
reflects 53 weeks of sales activity in 2007 compared to 52 weeks in 2006. The
price/mix impact was flat, reflecting a benefit from an increase in sales mix of
thermoformed product offset by the impact from lower average resin costs in 2007
versus 2006 which were passed through to customers as lower selling prices.
The following table presents sales, components of cost of sales, and the
resulting gross margin in dollars and on a per pound sold basis for 2007 and
2006. Cost of sales presented in the consolidated statements of operations
includes material and conversion costs and excludes amortization of intangible
assets. The material and conversion cost components of cost of sales are
presented in the following table. We have not presented these components as a
percentage of net sales because a comparison of this measure is distorted by
changes in resin costs that are typically passed through to customers as changes
to
selling prices. These changes can materially affect the percentages but do not present complete performance measures of the business.
2007 2006
Dollars and Pounds (in millions)
Net sales $ 1,452.0 $ 1,485.6
Material costs 952.1 968.3
Material margin 499.9 517.3
Conversion costs 336.3 340.8
Gross margin $ 163.6 $ 176.5
Pounds Sold 1,436 1,460
Dollars per Pound Sold
Net sales $ 1.011 $ 1.017
Material costs 0.663 0.663
Material margin 0.348 0.354
Conversion costs 0.234 0.233
Gross margin $ 0.114 $ 0.121
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Material margin and gross margin per pound sold decreased primarily because
of higher resin costs in the second half of 2007 which we were not able to fully
pass on to customers as higher selling prices due to a soft demand environment.
Conversion costs per pound sold during 2007 increased slightly from 2006 due to
an increase in per pound labor-related expenses and higher depreciation expense
partially offset by a shift in mix of sales to lower cost plants and reductions
in freight, repairs and maintenance and packaging expenses per pound sold.
Selling, general and administrative expenses were $83.8 million in 2007,
representing an $8.5 million increase over 2006. The 2007 expenses include a
$1.9 million charge associated with the resignation of the Company's former
President and Chief Executive Officer in the third quarter of 2007, a
$2.8 million foreign currency net loss due to a weaker U.S. dollar during 2007
and $0.4 million of selling, general and administrative expenses reported in our
Creative business. In our fourth quarter of 2007, we restructured our U.S.
dollar investment previously held by our Canadian operations which will mitigate
the majority of our consolidated foreign currency exposure that caused the net
currency losses in 2007. Excluding these factors, selling, general and
administrative expenses increased $3.6 million in 2007 due primarily to a
$2.5 million increase in information technology-related costs, including
depreciation expense, associated with our company-wide Oracle information system
implementation, higher professional fees and the impact from the inclusion of an
additional week during 2007, all of which were partially offset by lower
incentive compensation expenses.
In the first quarter of 2006, we adopted SFAS 123 (revised 2004), Share-Based
Payment ("SFAS 123(R)"). Prior to the adoption of SFAS 123(R), we had adopted
the disclosure-only provisions of SFAS 123, Accounting for Stock-Based
Compensation, and no expense related to stock options was recognized in our
results of operations. We implemented SFAS 123(R) using the modified prospective
transition method, which requires the expensing of stock options upon adoption
without restating prior periods. Stock-based compensation was $2.9 million in
2007, of which $2.6 million was recognized in selling, general and
administrative expenses and $0.3 million was recorded as cost of sales. In 2006,
stock-based compensation expense was $2.8 million, of which $2.5 million was
recognized in selling, general and administrative expenses and $0.3 million was
recorded as cost of sales.
In October of 2007, Pfizer, Inc. ("Pfizer"), a customer of Creative,
announced the exit of its new inhaled insulin product, Exubera, which resulted
in the impairment of a customer-related intangible asset assigned to the Pfizer
relationship upon acquisition.
In the fourth quarter of 2006, we recorded a $3.2 million non-cash goodwill
impairment charge due to changes in our profiles business and the reorganization
of the operations, management and reporting of this business which led to a
redefinition of our operating segments comprising our Engineered Products group
and allocation of goodwill to our new profiles reporting unit. The fair value of
our profiles business did not support the $3.2 million goodwill allocation which
resulted in the impairment charge.
Restructuring and exit costs were $1.3 million during 2007 and $1.9 million
in 2006 and largely represent employee severance, equipment moving and
accelerated depreciation charges. The 2007 restructuring and exit costs
primarily reflect the expenses associated with the consolidation of three
existing Custom Sheet and Rollstock production facilities into one newly
constructed facility in Greenville, Ohio. The 2006 restructuring and exit costs
primarily represent the expenses associated with the consolidation of three
Color and Specialty Compounds production facilities into one plant in Donora,
Pennsylvania.
Operating earnings for 2007 were $72.4 million compared to $91.4 million in
2006, representing a $19.0 million decrease. The decrease in operating earnings
is largely attributable to the $13.0 million decrease in gross margin and the
$8.5 million increase in selling, general, and administrative expenses,
. . .
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